[0001] This invention relates generally to supports for imaging elements, such as photographic,
electrostatophotographic and thermal imaging elements, and in particular to supports
comprising a polyester polymeric film, an adhesion promoting "subbing" layer, and
imaging elements comprising the subbed polymeric film and an image forming layer.
More particularly, this invention relates to subbed polymer supports and imaging elements
wherein the subbing layer is present on the support during a heat treatment.
[0002] Imaging elements generally comprise a support, adhesion or tie layers (subbing layers),
image recording layers, and auxiliary layers that serve other functions, such as scratch
resistance, static abatement, magnetic recording or lubrication. U.S. Patent Application
No. 09/067,306, titled "THERMALLY STABLE SUBBING LAYER FOR IMAGING ELEMENTS," J. Chen,
et al., filed April 27, 1998, discusses the severe requirements for adhesion to the
support and between layers in the imaging element. The inert character of most surfaces
such as polyester surfaces presents considerable challenge for adhesion of layers
coated thereon. As discussed in U.S. Patent Application No. 09/067,306, J. Chen, et
al., the adhesion difficulties have traditionally been overcome by the use of subbing
systems involving etch agents as disclosed in U.S. Patent No. 3,143,421, titled "ADHERING
PHOTOGRAPHIC SUBBING LAYERS TO POLYESTER FILM," by G. Nadeau, et al., August 4, 1964;
U.S. Patent No. 3,201,249, titled "COMPOSITE FILM ELEMENT AND COMPOSITION THEREFOR
INCLUDING ANTI-HALATION MATERIAL," by G. Pierce, et al., August 17, 1965, and U.S.
Patent No. 3,501,301, titled "COATING COMPOSITIONS FOR POLYESTER SHEETING AND POLYESTER
SHEETING COATED THEREWITH," by G. Nadeau, et al., March 17, 1970, or alternatively,
by energetic treatments, including corona discharge, glow discharge (see for example
U.S. Patent No. 5,425,980, titled "USE OF GLOW DISCHARGE TREATMENT TO PROMOTE ADHESION
OF AQUEOUS COATS TO SUBSTRATE," by J.Grace et al., June 20, 1995, and references cited
therein), ultraviolet radiation, electron beam, and flame treatment. Whether the support
is treated by coating with a polymeric subbing layer containing an etchant or whether
it is modified by energetic treatment, in many instances an additional subbing layer
comprised of gelatin, or a single mixed subbing layer including a non-gelatin polymer
and gelatin may be used. These gelatin and mixed subbing layers provide good adhesion
to subsequently coated layers comprising hydrophilic colloid binders.
[0003] It is also mentioned in U.S. Patent Application No.09/067,306, that recently introduced
systems such as the Advanced Photo System™ (APS) require thermal processing of the
polyester support. The thermal processing is required in order to meet the mechanical
specifications associated with the use of small format film in small cartridges, as
well as the film loading and unloading mechanisms employed by APS cameras and APS
film processors. The thermal treatment sufficiently reduces the core-set curling tendency
of the polymeric film such that the mechanical requirements for the system are met.
It is also stated that there are possible manufacturing benefits of coating the subbing
layers prior to the requisite heat treatment. However, as disclosed in the above mentioned
application, extended heat treatment or annealing processes applied to polyesters
with gelatin or mixed subbing layers have been found to severely compromise the adhesion
of subsequently coated hydrophilic colloid layers, such as silver halide emulsion
layers of silver halide photographic elements.
[0004] The thermal degradation of the gelatin-containing subbing may result from thermally
driven decomposition of the underlying support and subbing layer(s) and interaction
of the byproducts with the gelatin subbing layer. In the case of a single mixed subbing
layer, it may result from thermally driven chemical processes involving the non-gelatin
polymer and gelatin. Hence, it may be desirable to have a single subbing layer that
is both thermally stable and does not contain gelatin.
[0005] U.S. Patent No. 5,563,029, titled "MOLECULAR GRAFTING TO ENERGETICALLY TREATED POLYESTERS
TO PROMOTE ADHESION OF GELATIN-CONTAINING LAYERS," by J. Grace et al., April 3, 1995,
discloses the use of amine reactive hardeners in combination with nitrogen glow-discharge
treatment (or some other means of producing surface amines) applied to polyester support
to provide the adhesion function of the subbing system. Grace et al. show that bis(vinylsulfonyl)methane,
a representative amine reactive hardener, can be used as a molecular primer to bond
a gelatin-containing layer to a plasma-treated support. It is taught that the amine
reactive hardener chemically bonds to the plasma-treated support and that the gelatin
then bonds to the amine reactive hardener. Similar to its function as a cross linking
agent, the hardener links the gelatin to the treated surface by covalent bonds that
are established by reaction of the vinylsulfone groups in the hardner with amine groups
in the nitrogen-plasma-treated surface and in the gelatin coating. Grace et al. does
not suggest that amine reactive hardeners in combination with appropriate surface
treatment (e.g., glow discharge) provide a thermally stable subbing layer. In fact,
one skilled in the art would likely expect that the highly reactive hardeners disclosed
by Grace et al. would undergo undesirable chemical reactions under prolonged exposure
to heat (e.g., as required for the manufacture of film base for Advanced Photo System™
film).
[0006] It is therefore an object of the present invention to provide a method for forming
an imaging support element which includes a single subbing layer that is thermally
stable and does not contain gelatin.
[0007] It is a further object of the present invention to provide a method for forming an
imaging support element which includes a single subbing layer that retains its adhesion
promoting characteristics under the heat treatment conditions required for manufacture
of polyester film base, such as that used in the Advanced Photo System™ (APS).
[0008] It is an advantage of the present invention that the an imaging support element of
the present invention which includes a nitrogen plasma treated polymeric film having
an adhesion promoting layer formed thereon and is subjected to a heat treatment exhibits
a reduction in the core-set curling tendency of the polymeric film.
[0009] Briefly stated, the foregoing and numerous other features, objects and advantages
of the present invention will become readily apparent upon a reading of the detailed
description, claims and figures set forth herein. These features, objects and advantages
for producing an imaging support element are accomplished by forming a coating over
a polymeric film support, the coating having a surface including amine reactive groups
in a density of at least 10
10 per cm
2 and then heat treating the polymeric film support with the coating thereon at a temperature
of from about the glass transition temperature (T
g) of the polymeric film support minus 50 °C to about glass transition temperature
(T
g) of the polymeric film. The polymeric film support is nitrogen plasma treated. The
layer comprises an amine reactive hardener or a chlorine-free non-gelatin polymer
with amine reactive side groups. The layer is preferably formed by coating a monomer
solution on the nitrogen plasma treated polymer support wherein the coated monomer
has at least two vinyl sulfone groups which provide the amine reactive groups. Alternatively,
the layer may be formed by applying to the polymeric support web a coating including
at least one non-amine reactive comonomer and a comonomer having amine reactive side
groups. The coating or subbing layer should not have chlorine-containing, thermally
degradable constituents, either chemically bound or mixed in solution. Furthermore,
if the coating or subbing layer is used in combination with an underlying chlorine-containing
layer, the coating or subbing layer should be chemically stable in the presence of
the dehydrohalogenation products of the underlying chlorine-containing layer. The
amine-reactive groups must be present in sufficient quantity, preferably in a range
of from 10
10 to 10
17 sites/cm
2, and most preferably, in a range of from 10
13 to 10
15 sites/cm
2) to promote adhesion of the hydrophilic colloid layers. These required amine reactive
sites are those which are located at the surface of the coating or layer. The terms
"surface" and "at the surface" as used herein is intended to mean and include that
portion of the layer or coating within 2nm and preferably within 1nm of the top surface
of the coating or layer.
[0010] In a preferred embodiment of the invention, the polymer film support comprises poly(ethylene
naphthalate), the subbing layer comprises an amine-reactive monomer and non-amine-reactive
comonomers, wherein the amine reactive monomer provides amine reactive side groups
to the polymer formed upon polymerization with the comonomers, and the heat treatment
comprises subjecting the subbing layer coated support to a temperature of from 50
°C below the glass transition temperature (T
g) of the polymer support to the glass transition temperature (T
g) of the polymer support for a time from 0.1 to 1500 hours. The glass transition temperature
(T
g) of polyester film supports is, for example, generally in the range of from 80 °C
to 120°C.
[0011] In another embodiment of the present invention, an imaging element for use in an
image-forming process is described, the imaging element comprising a subbing layer
coated polyester polymeric film support as described above, and an image-forming layer(s)
(sometimes referred to as an imaging pack coated on the subbed support).
Fig. 1 is a graph of sulfur content of plasma-treated poly(ethylene naphthalate) that
has been exposed to a solution of hardener after treatment. The sulfur concentration
is plotted as a function of the incorporated nitrogen in the plasma-treated poly(ethylene
naphthalate);
Fig. 2 is a graph of vinylsulfone-based hardener coverage as a function of incorporated
nitrogen for plasma-treated poly(ethylene naphthalate) that has been exposed to a
solution of hardener after treatment;
Fig. 3 is a graph plotting adhesion failure as a function of composition of a subbing
layer (concentration of vinylsulfone group on an atomic basis) for a terpolymer subbing
layer coated support which was not heat treated prior to emulsion coating;
Fig. 4 is a graph plotting adhesion failure as a function of composition of a subbing
layer (concentration of vinylsulfone group on an atomic basis) for a terpolymer subbing
layer coated support which was heat treated prior to emulsion coating;
Fig. 5 is a graph plotting adhesion failure as a function of composition of a subbing
layer (concentration of vinylsulfone group on an atomic basis) for a copolymer subbing
layer coated support which was not heat treated prior to emulsion coating;
Fig. 6 is a graph plotting adhesion failure as a function of composition of a subbing
layer (concentration of vinylsulfone group on an atomic basis) for a copolymer subbing
layer coated support which was heat treated prior to emulsion coating;
Fig. 7 is a graph plotting of adhesion failure as a function of terpolymer subbing
layer coverage wherein the subbing coated support was not heat treated prior to an
emulsion coating simulation; and
Fig. 8 is a graph plotting of adhesion failure as a function of terpolymer subbing
layer coverage wherein the subbing coated support was heat treated prior to an emulsion
coating simulation.
[0012] In the practice of a preferred embodiment of the method of the present invention,
the polymer film comprises poly(ethylene terephthalate) or poly(ethylene naphthalate),
the discharge treatment is carried out in a nitrogen plasma, the non-chlorine-containing
and non-gelatin-containing subbing component comprises a vinylsulfonyl compound such
as described in U.S. Patent No. 5,723,211, titled "INK-JET PRINTER RECORDING ELEMENT,"
by C. Romano et al., March 3, 1998, other types of non-halogen-containing amine-reactive
hardeners such as described in U.S. Patent No. 5,418,078, titled "INK RECEIVING LAYERS,"
by Guido Desie et al., May 23, 1995, or a polymer containing such an amine-reactive
functional group, and the heat treatment comprises subjecting the subbing layer coated
support to a temperature from 50 °C below the glass transition temperature (T
g) up to the glass transition temperature (T
g) of the polymeric film from 0.1 to 1500 hours.
[0013] The subbing layer coated supports of the present invention can be used for many different
types of imaging elements. While the invention is applicable to a variety of imaging
elements such as, for example, photographic, ink jet, electrostatophotographic, photothermographic,
migration, electrothermographic, dielectric recording and thermal-dye-transfer imaging
elements, the invention is primarily applicable to photographic elements, particularly
silver halide photographic elements. Accordingly, for the purpose of describing this
invention and for simplicity of expression, photographic elements will be primarily
referred to throughout this specification; however, it is to be understood that the
invention also applies to other forms of imaging elements.
[0014] The annealable (actually heat treatable) subbing formulation does not contain gelatin
and does not suffer from the degradation processes driven by acetaldehyde from the
polymer base or decomposition products of underlying vinylidene chloride layers, both
of which are known to diffuse into a gelatin subbing layer during the annealing process
of APS film base.
[0015] The subbing formulation can be a monomeric formulation (i.e., a single amine-reactive
monomer) or a polymeric formulation in which an amine reactive monomer is polymerized
with non-amine reactive comonomers. The monomeric formulation requires that the monomer
bond to the polymer support surface (which may be activated by plasma treatment) while
having an amine-reactive group available for bonding with subsequently coated layers.
This approach is demonstrated in Example 1 below.
[0016] The polymeric formulation allows one to dilute the amine reactive monomer with non-amine
reactive comonomers to form a polymeric film. The polymeric formulation requires that
the amine reactive functionality is available for both anchoring the polymer to the
polymer support surface and for bonding with subsequently coated layers. This approach
is demonstrated in Examples 2 and 3 below.
[0017] With either approach, (monomer or polymer), the essential feature is a surface density
of available amine-reactive groups to form bonds with a subsequently coated layer.
In the case of the monomer, it is possible to quantify the surface density of functional
groups, provided that the monomer has a chemical constituent that is identifiable
without interference from elements in the polymeric support (see Example 1).
[0018] In the case of the polymeric formulations, however, the non-amine reactive comonomers
may have common elements to those in the amine-reactive comonomer and it may be difficult
to quantify the net surface density of amine-reactive functional groups. In this case,
the formulation variables can be used to quantify the polymer composition, and it
can only be assumed that the amine-reactive side groups are present in the surface
in proportion to their compositional presence in the polymer formulation.
[0019] Examples of amine-reactive hardeners useful in this invention are bis(vinylsulfonyl)methane
(BVSM) and other vinylsulfonyl compounds such as described in U.S. Patent No. 5,723,211,
Romano et al. Especially useful are co-and terpolymers incorporating units depicted
by:

where
R is H or CH3,
A is a direct link or is C(O)O or C(O)NH,
B is an aliphatic group of from 1 to 10 carbon atoms, or an aromatic group such as
phenyl, benzyl, naphthyl, or pyridinyl,
C is a direct link or is an aliphatic group of from 1 to 10 carbon atoms or is chosen
from the following structural units:
―O―(CH
2)
n―
―SO
2―(CH
2)
n―

or

where m and n are separately integers from 0 to 10, and the amine-reactive hardener
is polymerized with non-amine reactive comonomers. Non-amine-reactive comonomers useful
in this invention are hydrophilic species such as acrylamide, acrylamidoglycolic acid,
2-acrylamido-2-methylpropanesulfonic acid, sodium salt (herein referred to as AMPS),
acrylic acid, 4-acryloxybutane-1-sulfonic acid, sodium salt, 2-acryloxyethane-1-sulfonic
acid, sodium salt, 3-acryloxypropane-1-sulfonic acid, sodium salt, N,N-dimethylacrylamide,
2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, methacrylic acid, 4-methacryloxybutane-1-sulfonic
acid, sodium salt, 2-methacryloxyethane-1-sulfonic acid, sodium salt, 3-methacryloxyl-1-methylpropane-1-sulfonic
acid, sodium salt, 3-methacryloxypropane-1-sulfonic acid, sodium salt, 1-vinyl-2-pyrrolidinone,
or other water-soluble or hydrophilic monomers.
[0020] The examples below demonstrate that the combination of nitrogen plasma surface modification
and a single subbing layer, the subbing layer comprising amine reactive hardener molecules
or polymers having amine-reactive side groups, can withstand the thermal treatment
required to condition the polyester support, while retaining the requisite adhesive
properties for subsequently coated hydrophilic colloid layers. The amine-reactive
groups must be present in sufficient quantity (10
10 to 10
17 sites/cm
2) to promote adhesion of the hydrophilic colloid layers. The lower limit corresponds
to a fraction of a monolayer of coverage of the amine-reactive groups, whereas the
upper limit corresponds to many layers (roughly 100) of amine-reactive group. Work
in our lab correlating adhesion performance of hydrophillic colloid layers on surfaces
functionalized with amine-reactive hardeners suggests a preferred surface density
range of 10
13 to 10
15 sites/cm
2. In the case of bis(vinylsulfonyl)methane (BVSM) grafted to nitrogen-plasma-treated
poly(ethylene napthalate) support, this range corresponds to a range of coverage from
0.01 to 1 monolayers of BVSM.
[0021] While the surface density of the required amine-reactive groups is the key physical
parameter that determines the level of interfacial adhesion, a given surface density
of a specific reactive group can be obtained in a variety of ways. If the subbing
layer is constructed such that the distribution of desired amine-reactive groups is
random and evenly distributed throughout the layer, the preferred range of 10
13 to 10
15 sites/cm
2 translates to a particular range of sites per atom in the near-surface region, i.e.,
within 1 nm of the surface of the subbing layer. Specifically, it has been found that
the amine-reactive side groups preferably comprise a ratio of reactive groups per
atom in the repeat unit from 0.003 to 0.1. This ratio is defined by taking the number
of vinylsulfone groups in a comonomer and dividing it by the total number of atoms
in the polymer repeat unit.
[0022] In contrast to the random and uniform distribution of reactive groups, layers can
be constructed to have a core-shell structure. While the material in the core need
not have the reactive groups of interest, the shell may be constructed to have a significant
amount of the required reactive groups. In this way, the required surface coverage
of reactive sites may be provided with a significantly lower ratio of reactive groups
to atoms in the repeat unit or with a significantly lower ratio of reactive groups
to atoms in the core-shell structural unit. For these structures, the most appropriate
specification is the coverage in sites/cm
2 as described above.
[0023] While the examples below use a random and uniform distribution of reactive side groups
and can thus be specified in terms of ratio of reactive side group to atoms in the
repeat unit, it should be apparent to those skilled in the art that alternative ways
of constructing the polymeric subbing layer can be found which would provide similar
adhesion results with similar amine-reactive sites/ cm
2 on the subbing layer surface, but with significantly reduced ratios of reactive groups
to number of atoms in the subbing structural unit.
[0024] Photographic elements which can be provided with a subbing layer in accordance with
the invention can differ widely in structure and composition. For example, they can
vary greatly in the type of support, the number and composition of image-forming layers,
and the kinds of auxiliary layers that are included in the elements. In particular,
the photographic elements can be still films, motion picture films, x-ray films, graphic
arts films, prints, or microfiche. They can be black-and-white elements or color elements.
They may be adapted for use in a negative-positive process or for use in a reversal
process.
[0025] Polyester film supports which are useful for the present invention include polyester
supports such as, poly(ethylene terephthalate), poly(1,4-cyclohexanedimethylene terephthalate),
poly(ethylene 1,2-diphenoxyethane-4,4'-dicarboxylate), poly(butylene terephthalate),
and poly(ethylene naphthalate) and the like; and blends or laminates thereof with
other polymers. Particularly preferred embodiments are poly(ethylene terephthalate)
and poly(ethylene naphthalate), and poly(ethylene naphthalate) is especially preferred
for use as the support for photographic imaging elements designed for use in the Advanced
Photo System™. Preferred polymer film support thickness is less than 400 microns,
more preferably less than 200 microns and most preferably less than 150 microns. Practical
minimum support thickness is 50 microns. The supports can either be colorless or colored
by the addition of a dye or pigment.
[0026] The use of heat processes during conventional polymer film manufacture to modify
the physical characteristics of polymer film elements is itself well known. For example,
in the continuous manufacture of certain thermoplastic film, particularly polyester
film by processes involving extrusion from bulk storage of polymer stock material,
it is necessary in order to obtain desired physical properties, such as transparency,
tensile strength and dimensional stability, that the usually amorphous, extruded body
of film subsequently be heated and worked by prescribed treatments. In such heating
and working treatments, the heated film usually is first stretched lengthwise 2 to
4 times its original length, and then similarly stretched widthwise. The stretching,
known as "cold drawing", is carried out at temperatures below the temperature of melting
but above the glass transition temperature of the polymer. The resulting film is then
described as being biaxially-oriented. The cold drawing effects some change in the
crystallinity of the polymer. Next, to enhance the crystallinity and to increase the
dimensional stability of the film, the biaxially-oriented polymeric film is "heat-set"
by heating it near its crystallization point, while maintaining it under tension.
The heating and tensioning also ensure that the heat-set film remains transparent
upon cooling. After being directionally oriented and heat-set polymer films are then
also conventionally subjected to a subsequent heat treatment known in the art as a
"heat-relax" treatment.
[0027] The supports of the present invention may optionally be coated with a wide variety
of additional functional or auxiliary layers such as antistatic layers, abrasion resistant
layers, curl control layers, transport control layers, lubricant layers, image recording
layers, additional adhesion promoting layers, layers to control water or solvent permeability,
and transparent magnetic recording layers. In a preferred embodiment of the invention,
the backside of the support (opposite side to which image forming emulsion layers
are coated) is coated with an antistatic layer, a transparent magnetic recording layer
and an optional lubricant layer. A permeability control layer may also be preferably
coated between the antistatic layer and transparent magnetic recording layer. Magnetic
layers suitable for use in elements in accordance with the invention include those
as described, e.g., in
Research Disclosure, November 1992, Volume No. 34390. Representative antistatic layers, magnetic recording
layers, and lubricant layers are described in U.S. Patent No. 5,726,001, titled "COMPOSITE
SUPPORT FOR IMAGING ELEMENTS COMPRISING AN ELECTRICALLY-CONDUCTIVE LAYER AND POLYURETHANE
ADHESION PROMOTING LAYER ON AN ENERGETIC SURFACE-TREATED POLYMERIC FILM," by
D. Eichorst, March 10, 1998, the disclosure of which is incorporated herein by reference.
It is also specifically contemplated to use supports according to the invention in
combination with technology useful in small format film as described in
Research Disclosure, June 1994, Volume No. 36230.
Research Disclosure is published by Kenneth Mason Publications, Ltd., Dudley House, 12 North Street,
Emsworth, Hampshire P010 7DQ, ENGLAND.
[0028] Photographic elements in accordance with the preferred embodiment of the invention
can be single color elements or multicolor elements. Multicolor elements contain image
dye-forming units sensitive to each of the three primary regions of the spectrum.
Each unit can comprise a single emulsion layer or multiple emulsion layers sensitive
to a given region of the spectrum. The layers of the element, including the layers
of the image-forming units, can be arranged in various orders as known in the art.
In an alternative format, the emulsions sensitive to each of the three primary regions
of the spectrum can be disposed as a single segmented layer.
[0029] A typical multicolor photographic element comprises a support bearing a cyan dye
image-forming unit comprised of at least one red-sensitive silver halide emulsion
layer having associated therewith at least one cyan dye-forming coupler, a magenta
dye image-forming unit comprising at least one green-sensitive silver halide emulsion
layer having associated therewith at least one magenta dye-forming coupler, and a
yellow dye image-forming unit comprising at least one blue-sensitive silver halide
emulsion layer having associated therewith at least one yellow dye-forming coupler.
The element can contain additional layers, such as filter layers, interlayers, antihalation
layers, overcoat layers, additional subbing layers, and the like.
[0030] In the following discussion of suitable materials for use in the photographic emulsions
and elements that can be used in conjunction with the subbed supports of the invention,
reference will be made to
Research Disclosure, September 1994, Volume No. 36544, available as described above, which will be identified
hereafter by the term
"Research Disclosure." The Sections hereafter referred to are Sections of the
Research Disclosure, Volume No. 36544.
[0031] The silver halide emulsions employed in the image-forming layers of photographic
elements can be either negative-working or positive-working. Suitable emulsions and
their preparation as well as methods of chemical and spectral sensitization are described
in Sections I, and III-IV. Vehicles and vehicle related addenda are described in Section
II. Dye image formers and modifiers are described in Section X. Various additives
such as UV dyes, brighteners, luminescent dyes, antifoggants, stabilizers, light absorbing
and scattering materials, coating aids, plasticizers, lubricants, antistats and matting
agents are described, for example, in Sections VI-IX. Layers and layer arrangements,
color negative and color positive features, scan facilitating features, supports,
exposure and processing can be found in Sections XI-XX.
[0032] In addition to silver halide emulsion image-forming layers, the image-forming layer
of imaging elements in accordance with the invention may comprise, e.g., any of the
other image forming layers described in U.S. Patent No. 5,457,013, titled "IMAGING
ELEMENT COMPRISING A TRANSPARENT MAGNETIC LAYER AND AN ELECTRICALLY-CONDUCTIVE LAYER
CONTAINING PARTICLES OF A METAL ANTIMONATE," by P. Christian et al., October 10, 1995,
the disclosure of which is incorporated by reference herein.
[0033] The following examples will illustrate the advantages of using the method and adding
the materials of the present invention over the use of conventional gelatin subbing
layer formulations.
Example 1: Pure BVSM
[0034] Plasma-treated poly(ethylene-2, 6-naphthalate) (PEN) was prepared by passing the
PEN support through a glow-discharge zone in a vacuum web coating machine. A pair
of coplanar, water-cooled aluminum electrodes, each 33 cm wide (cross web) x 7.6 cm
long (along the web direction) were housed in an electrically grounded aluminum enclosure.
The 100 µ thick, 13 cm wide support passed through entrance and exit slits in the
side of the enclosure and was thus conveyed 3 cm above the electrodes. The enclosure
extended roughly 1 cm behind the support. Treatment gas was admitted to the enclosure
through a series of pinholes in one of the cross-web sides of the enclosure. A 40
kHz high voltage supply was used to apply voltage across the coplanar electrodes,
which were electrically isolated from the grounded enclosure.
[0035] Treatments were carried out in nitrogen at a pressure of 0.10 Torr and a flow of
roughly 330 std. cc/min. Web speeds were varied between 3 and 15 m/min and powers
were varied between 60 W and 465 W in order to control treatment dose. The treatment
dose (in J/cm
2) was calculated by multiplying the power and the residence time in seconds (2 x [0.076/web
speed] x 60, where web speed is in m/min.) and dividing by the 500 cm
2 area of the pair of electrodes. Resultant doses ranged from 0.07 to 2.8 J/cm
2.
[0036] Starting solutions of 1.8 wt % bis(vinylsulfonyl)methane (BVSM) in water were further
diluted by adding 1.72 g of starting solution to 98.28 g of deionized water. As a
subbing layer, the resultant solution (0.03 wt. % BVSM) was coated at 0.27 cc/dm
2 onto 13 cm x 46 cm sheets, using a #12 wire wound rod from R.D. Specialties. The
sheets were placed on a temperature-controlled coating block and were held thereto
by suction grooves near the perimeter of the block. The block temperature was 49 °C.
Coatings were dried on the warm block for several minutes until the bulk of the water
was removed and the surfaces appeared to be dry.
[0037] In addition, samples of nitrogen-plasma-treated PEN were immersed in solutions of
0.1 wt % bis(vinylsulfonyl)methyl ether (BVSME) in water for 5 minutes at room temperature.
They were then dried for 5 min at 40 °C and then washed with deionized water for 1
min and dried in air. A second set of samples was prepared by immersing nitrogen-plasma-treated
PEN in 0.1 wt % BVSM for 0.5 min at room temperature and then drying the samples for
5 minutes at 93 °C. These samples were also washed in deoinized water for 1 min and
dried in air. The above mentioned samples were examined using x-ray photoelectron
spectroscopy (XPS). The vinylsulfone attachment to the treated surface could be assessed
by the amount of sulfur detected. The amount of sulfur could then be converted into
an approximate coverage of hardener (in monolayers) by using molecular orbital calculations
to determine the size of each type of hardener molecule. One monolayer of BVSM, with
one end attached to the support and the other end unreacted, corresponds to 10
15 available reactive groups/cm
2. As can be seen in Figs. 1 and 2, the coverage of BVSM or BVSME increases linearly
with nitrogen content of the plasma treated PEN, consistent with increased surface
density of amine groups with increasing plasma treatment dose. The XPS studies on
the washed samples establish that the vinylsulfone-based hardeners bond with the plasma-treated
support. The coating and adhesion experiments described below, as well as the prior
work disclosed in U.S. Patent No. 5,563,029, Grace et al., establishes that a significant
amount of the vinylsulfone groups are available for bonding to gelatin-based overcoats.
Based on the XPS studies, we establish that the treatment conditions shown in Table
1, in combination with the BVSM coating process, as described above span a BVSM coverage
range of <0.1 monolayer to 1 monolayer, or < 10
14 to 10
15 available vinylsulfone groups per cm
2. (For sufficiently low treatment doses, there is the additional problem that the
BVSM molecule may have both ends bonded to the treated polymer surface, which will
further reduce the available groups per cm
2. The lower density range of available surface groups is addressed by Example 2 below.)
[0038] To simulate heat treatment in a roll format, BVSM-coated sheets of PEN were placed
in a pile and were interleaved with clean, untreated sheets of PEN. The stack of coated
and uncoated sheets was then placed in an oven at 100 °C for 2 days. A second set
of samples was left at room temperature and was not subjected to thermal treatment.
[0039] To simulate coating with silver halide emulsion (a hydrophilic colloid layer), the
BVSM-coated support was overcoated with the bottom layer of Gold 400 photographic
film at a dry coverage of roughly 86 mg/dm
2. This layer contained gelatin, dyes, coupler solvents, surfactant and other addenda
typical of the bottom layer in Gold 400 film. The layer was coated at 21 °C, chill-set
for 3:15 at 4 °C, dried at 18 °C for 2:40, and further dried at 49 °C for 6:00 (minutes:seconds).
After emulsion coating the samples were placed in a stack and were kept in 21 °C/50
% relative humidity conditions for 10 days in order to allow the emulsion layer to
harden.
[0040] Practical adhesion was evaluated by use of a mechanical abrasion test in photographic
developer. The test was carried out by soaking samples in Flexicolor™ (C-41) developer
(at 38 °C) for 3:15 (minutes:seconds). The samples were then placed in a developer-filled
tray, and a weighted 35 mm dia. Scotchbrite™ pad from 3M rubbed back and forth along
the sample surface (roughly 3 cm stroke) for 30 cycles in roughly 30 sec. The applied
weight was 400 g. Samples were rinsed in water and dried. The amount of coating removed
in the rubbed area was assessed by use of an optical scanner (Logitech ScanMan), and
adhesion failure results were reported as % removed. Typically, scratching from abrasive
wear and cohesive failure of the simulated photographic emulsion layer will register
as 0 to 5%. Adhesion failure will result in removal above this level, with 10 to 100
% removal indicating significant adhesion failure.
[0041] The nitrogen discharge treatment conditions and resultant adhesion failure for emulsion
coatings on annealed and unannealed subbing are listed in Table 1. The untreated control
sample was made by coating the representative hydrophilic colloid layer on untreated
and unsubbed PEN support and demonstrates the importance of the subbing layer and
surface treatment process.
[0042] Samples 1U-5U were coated with BVSM subbing but were not thermally processed prior
to coating the representative photographic emulsion (hydrophilic colloid layer). These
samples confirm the findings of Grace et al., U. S. Patent No. 5,563,029, wherein
amine reactive hardeners in combination with nitrogen plasma-treated polyesters are
found to promote adhesion of subsequently coated hydrophilic colloid layers.
[0043] Samples 1A - 5A were coated with BVSM subbing and then were thermally treated (annealed)
prior to coating the hydrophilic colloid layer. The impact of the annealing process
for adhesion of subsequently coated hydrophilic colloid layers is minor (compare results
for samples 1U - 3U with those for respective annealed samples 1A - 3A), and conditions
can be found that produce excellent adhesion (particularly 4A and 5A). This result
is unanticipated, as one skilled in the art might expect the reactive BVSM layer to
polymerize or undergo other reactions during the heat treatment process. One would
further expect unreacted BVSM to leave the surface by evaporation. At sufficient nitrogen
plasma treatment doses, however, good adhesion is obtained even on heat treated, BVSM-coated
support.
Table 1.
Treatment conditions and resultant adhesion for a representative photographic emulsion
coated onto BVSM-coated, nitrogen-plasmatreated PEN. |
Sample |
Discharge Pressure (mTorr) |
Discharge Power (W) |
Web Speed (m/min) |
Dose (J/cm2) |
Adhesion Failure (%) |
1U |
100 |
60 |
15.2 |
0.072 |
43 |
2U |
100 |
120 |
15.2 |
0.144 |
0 |
3U |
100 |
160 |
5.06 |
0.578 |
0 |
4U |
100 |
330 |
5.06 |
1.19 |
0 |
5U |
100 |
465 |
3.05 |
2.79 |
0 |
|
1A |
100 |
60 |
15.2 |
0.072 |
68 |
2A |
100 |
120 |
15.2 |
0.144 |
6 |
3A |
100 |
160 |
5.06 |
0.578 |
4 |
4A |
100 |
330 |
5.06 |
1.19 |
0 |
5A |
100 |
465 |
3.05 |
2.79 |
1 |
|
Untreated Control |
N/A |
N/A |
N/A |
N/A |
100 |
Example 2: Polymeric Hardener with Amine-Reactive Side Groups
[0044] Plasma treatments were carried out on PEN as discussed in Example 1 above. A terpolymer
having 10 wt % acrylamide (A), 80 wt % 2-acrylamido-2-methylpropanesulfonic acid,
sodium salt (AMPS), and 10 wt % dehydrohalogenate of 4-acrylamidobenzyl-(2-chloro)ethylsulfone
(herein referred to as vinylsulfone-containing monomer, or VSM) was formed by dissolving
the appropriate ratio of monomers in a solution of water/acetone (2/1 by weight) to
make the final solution 15 wt % in total monomer. This was sparged with nitrogen gas
for at least 20 minutes, followed by the addition of K
2S
2O
8 (0.1 - 0.3 wt % based on monomer). The reaction mixture was heated under N
2 at 60-65 °C for 16 - 18 hr, then cooled.
[0045] Dehydrohalogenation was effected by adjusting the pH of the polymerization solution
to 11 with a dilute NaOH solution, stirring for 30 minutes, and readjusting the pH
back to 7 with dilute acetic acid. Solutions were then used as is, or were dialyzed
or diafiltered to remove impurities. (Note that the final terpolymer contains no chlorine
after dehydrohaleogenation.)
[0046] Starting solutions of 1.8 wt % of terpolymer in water were further diluted by adding
1.72 g of starting solution to 98.28 g of deionized water. A second dilute solution
was prepared by adding 0.172 g of starting solution to 99.828 g of deionized water.
As subbing layers, the resultant solutions (respectively 0.03 wt % and 0.003 wt %
terpolymer) were coated onto PEN sheets as described in Example 1.
[0047] As in Example 1, heat treatment was carried out by placing subbing-coated sheets
of PEN in a pile, interleaved with clean, untreated sheets of PEN. The stack of coated
and uncoated sheets was then placed in an oven at 100 °C for 2 days. A second set
of samples was left at room temperature and was not subjected to thermal treatment.
[0048] Practical adhesion was assessed as described in Example 1. The resultant adhesion
data are shown in Table 2. From the table, it can be seen that some combinations of
treatment dose and dry coverage of the subbing layer (terpolymer) can be found to
produce good adhesion, with or without heat treatment of the subbing coated support
(for example, unannealed samples 9U and 14U and their respective annealed samples
9A and 14A). The results do show some sensitivity to dry coverage of terpolymer and
treatment dose. At low plasma treatment doses (samples 6U, 6A, 11U and 11A) both annealed
and unannealed samples show significant adhesion failure. There is also evidence that
excessive treatment doses produce poor adhesion upon annealing (compare results for
samples 10U and 10A). Hence, the plasma treatment and subbing layer processes would
require some optimization, as one skilled in the art would be able to accomplish.
Table 2
Treatment conditions, terpolymer (A-AMPS-VS) coverage, and resultant adhesion for
a representative photographic emulsion coated onto terpolymer-coated, nitrogen-plasma-treated
PEN. |
Sample |
Discharge Pressure (mTorr) |
Discharge Power (W) |
Web Speed (m/min) |
Dose (J/cm2) |
Dry Coverage of Terpolymer (mg/dm2) |
Adhesion Failure (%) |
6U |
100 |
60 |
15.2 |
0.072 |
0.008 |
69 |
7U |
100 |
120 |
15.2 |
0.144 |
0.008 |
0 |
8U |
100 |
160 |
5.06 |
0.578 |
0.008 |
1 |
9U |
100 |
330 |
5.06 |
1.19 |
0.008 |
2 |
10U |
100 |
465 |
3.05 |
2.79 |
0.008 |
4 |
|
6A |
100 |
60 |
15.2 |
0.072 |
0.008 |
59 |
7A |
100 |
120 |
15.2 |
0.144 |
0.008 |
8 |
9A |
100 |
330 |
5.06 |
1.19 |
0.008 |
0 |
10A |
100 |
465 |
3.05 |
2.79 |
0.008 |
33 |
|
11U |
100 |
60 |
15.2 |
0.072 |
0.08 |
57 |
12U |
100 |
120 |
15.2 |
0.144 |
0.08 |
18 |
13U |
100 |
160 |
5.06 |
0.578 |
0.08 |
8 |
14U |
100 |
330 |
5.06 |
1.19 |
0.08 |
5 |
|
11A |
100 |
60 |
15.2 |
0.072 |
0.08 |
11 |
12A |
100 |
120 |
15.2 |
0.144 |
0.08 |
0 |
14A |
100 |
330 |
5.06 |
1.19 |
0.08 |
0 |
Example 3: Varying the polymeric hardener composition
[0049] Plasma treatments were carried out on PEN as discussed in Example 1. Terpolymers
having acrylamide (herein referred to as A), 2-acrylamido-2-methylpropanesulfonic
acid, sodium salt (herein referred to as AMPS), and dehydrohalogenate of 4-acrylamidobenzyl-(2-chloro)ethylsulfone
(the vinylsulfone-containing monomer, or VSM). As before, note that the final terpolymer
contains no chlorine after dehydrohaleogenation. In addition, copolymers of 2-acrylamido-2-methylpropanesulfonic
acid, sodium salt, and dehydrohalogenate of 4-acrylamidobenzyl-(2-chloro)ethylsulfone
were prepared. For the terpolymer and the binary copolymer, the molar percentage of
dehydrohalogenate of 4-acrylamidobenzyl-(2-chloro)ethylsulfone ranged from 7 to 25.
The various terpolymers and copolymers used are listed in Table 3.
[0050] To form the terpolymers and copolymers, the appropriate ratio of monomers was dissolved
in a solution of water/acetone (2/1 by weight) to make the final solution 15 wt %
in total monomer. This was sparged with nitrogen gas for at least 20 minutes, followed
by the addition of K
2S
2O
8 (0.1 - 0.3 wt % based on monomer). The reaction mixture was heated under N
2 at 60-65 °C for 16 - 18 hours, then cooled.
[0051] Dehydrohalogenation was effected by adjusting the pH of the polymerization solution
to 11 with a dilute NaOH solution, stirring for 30 minutes, and readjusting the pH
back to 7 with dilute acetic acid. Solutions were then used as is, or were dialyzed
or diafiltered to remove impurities.
Table 3
Terpolymer and copolymer compositions applied to nitrogen plasma-treated PEN. The
vinylsulfone ratio is the number of vinylsulfone groups divided by the total number
of atoms in the repeat unit of the polymer. |
Polymer ID |
Mole % |
Weight % |
Vinylsulfone Ratio |
|
A |
AMPS |
VSM |
A |
AMPS |
VSM |
|
TER-7 |
27 |
66 |
7 |
10 |
80 |
10 |
0.0031 |
TER-17 |
23 |
60 |
17 |
8 |
68 |
24 |
0.0072 |
TER-25 |
19 |
56 |
25 |
6 |
60 |
34 |
0.0102 |
CO-9 |
0 |
91 |
9 |
0 |
89 |
11 |
0.0033 |
CO-17 |
0 |
83 |
17 |
0 |
79 |
21 |
0.0062 |
[0052] Dilute solutions of the terpolymers and copolymers were coated on the plasma-treated
support at a wet coverage of 0.27 cc/dm
2. For TER-8 polymer, two different dilutions (using de-ionized water) were prepared
to obtain dry coverages of 0.083 and 0.83 mg/dm
2. For the other four polymers, only samples having dry coverages of 0.083 mg/dm
2 were prepared. The polymer layers were coated at a line speed of 9 m/min. and were
dried at 93 °C in an in-line dryer section. At the stated coating speed, the residence
time in the dryer was 4:10 (minutes:seconds). No surfactant was added to the coatings,
except for the case of TER-17 coated on PEN with the high plasma treatment dose (2.79
J/cm
2). In that case, the surfactant used was Olin 10-G.
[0053] Heat treatment was carried out by placing 3 m lengths of each coating onto a composite
roll attached to a 7.6 cm diameter cardboard core. The wound roll was then placed
in an oven and kept at 110 °C for 3 days and then 100 °C for 2 days. A second composite
roll was prepared and left at room temperature and was not subjected to thermal treatment.
Both of these rolls were then overcoated with a representative hydrophilic colloid
layer (the same formulation as was used in Examples 1 and 2). In this example, the
representative photographic emulsion was coated by extrusion hopper on a machine at
a line speed of 3.7 m/min, with respective chill set, first dryer, and second dryer
temperatures of 4 °C, 21 °C, and 38 °C, for respective times of 3:15, 2:40, and 3:10
(minutes:seconds).
[0054] As in Examples 1 and 2, wet adhesion failure was assessed after the samples were
kept for 10 days in 21 °C / 50 % relative humidity conditions. The adhesion failure
results are plotted in Figs. 1-6. Figs. 1 and 2 show respective adhesion failure without
and with heat treatment for the TER series with three different nitrogen plasma treatment
doses. Figs. 3 and 4 show respective adhesion failure without and with heat treatment
for the CO series with three different nitrogen plasma treatment doses. Figs. 5 and
6 show respective adhesion failure without and with heat treatment for the TER-8 polymer
at two dry coverages with three different nitrogen plasma treatment doses.
[0055] From the graphs, (Figs. 1 - 8) and data presented therein, the following results
are evident. First, heat treatment of the polymeric subbing layer generally improves
adhesion performance. Second, increasing the vinylsulfone ratio from 0.003 to 0.007
or 0.010 generally improves the adhesion performance. Third, at a sub-optimal vinylsulfone
ratio fraction of 0.003, increasing the dry coverage from 0.083 to 0.83 mg/dm
2 improves the adhesion performance. In addition, at the same sub-optimal vinylsulfone
ratio, the plasma treatment dose can be adjusted to obtain acceptable adhesion with
or without heat treatment. Furthermore, the most robust adhesion with respect to plasma
treatment dose, subbing layer coverage and heat treatment is obtained for vinylsulfone
ratios above 0.003. (This example suggests that the composition of terpolymer used
in Example 2 -- vinylsulfone ratio of 0.003 -- is sub-optimal, but could be coated
sufficiently thick on an appropriately treated support to produce good adhesion before
or after heat treatment, consistent with the conclusions drawn from Example 2). Finally,
the nature of the polymer backbone is not important, provided it is stable at the
requisite processing temperatures.
[0056] The enhanced adhesion subsequent to heat treatment suggests that the dominant thermally
driven chemical processes involve linking polymer chains in the subbing layer to the
treated support surface or to other polymer chains in the subbing layer, without compromising
the availability of reactive groups at the subbing surface. These reactive groups
(from the vinylsulfone side group) are essential for adhesion of the hydrophilic colloid
layer coated to the subbing layer. This surprising result demonstrates that the objectives
of this invention (i.e., the above mentioned objectives hinging upon a thermally stable
chlorine-free, gelatin-free subbing layer) can be met by use of polymeric hardeners
with vinylsulfone ratio of 0.003 or higher, or by providing an equivalent surface
density of reactive groups.
[0057] The many features and advantages of the invention are apparent from the detailed
specification and thus it is intended by the appended claims to cover all such features
and advantages which fall within the true spirit and scope of the invention. Further,
since numerous modifications and changes will readily occur to those skilled in the
art, it is not desired to limit the invention to the exact construction and operation
illustrated and described, and accordingly all suitable modifications and equivalents
may be resorted to, falling within the scope of the invention.
[0058] The invention has been described in detail with particular reference to certain preferred
embodiments thereof, but it will be understood that variations and modifications can
be effected within the spirit and scope of the invention.